Panel of laminate structure

ABSTRACT

The invention concerns a panel of laminate structure, wherein there is provided a decorative top side which has at least one imitation intermediate joint by which the top side is subdivided into decorative regions and wherein each decorative region has the appearance of an individual covering element, wherein the imitation intermediate joint is in the form of a groove in the decorative top side.

The invention concerns a panel of laminate structure, wherein there is provided a decorative top side which has at least one imitation intermediate joint by which the top side is subdivided into decorative regions and wherein each decorative region has the appearance of an individual covering element.

Panels of the general kind set forth are known in the form of floor, wall or ceiling panels. The decorative top side of panels of that kind comprises graphic illustrations or veneer wood. In any case the top side is subdivided into a plurality of decorative regions, wherein the individual decorative regions adjoin each other and imitate an intermediate joint.

An example of a panel of the general kind set forth has a top side which imitates a plurality of tiles and intermediate joints of jointing mortar. Another known example is a panel with wood decoration which involves the visual appearance of a ship's bottom. Panels with the visual appearance of a ship's bottom can have a top side of wood veneer or a top side with a graphic reproduction of wood. In that case the individual wood strips or the graphics thereof are disposed in rows in mutually juxtaposed relationship. The wood strips are in butting relationship against each other and have a smooth intermediate joint. Both a visual appearance of a ship's bottom of wood veneer and also that comprising a photographed wood has the appearance that the wood strips involve individual covering elements. That however is not the case as the decorative layer is respectively mounted on a carrier or a core material and the intermediate joint is only an imitation of a real joint.

It is further known to impart to panels which have decorative regions involving graphic images, a surface embossing which forms perceptible intermediate joints and decorative regions. The impression of authenticity of such embossed intermediate joints however leaves something to be desired.

The object of the present invention is to provide a panel whose intermediate joints have a more natural appearance.

According to the invention that is achieved in that the imitation intermediate joint is in the form of a groove in the top side.

In that way, provided in the top side of a panel are joints whose shape and depth are precisely identical to the intermediate joints which occur in the case of known covering elements in the laid condition of the panels. An imitation intermediate joint of tiles is of a concave shape. An intermediate joint for the imitation of bevelled covering elements of wood is of a wedge-shaped cross-section and is also referred to as a V-joint. The joints are highly plastic. They can be felt more distinctly than embossed intermediate joints which involve only a very small embossing depth. In addition the intermediate joints in the form of a groove ensure that a shadow is cast, which can be clearly seen, with light incidence at an inclined angle, and that ensures an excellent impression of reality in regard to the panel covering.

The groove in the top side exceeds the depth which can be produced by an embossing procedure. In the case of a panel with a top side with graphics thereon, the groove passes through the graphic layer and extends into the core material of the panel. In the case of a panel with a top side of wood veneer, it is also possible to provide a groove depth which exceeds the thickness of the wood veneer layer so that the bottom of the groove extends into the core material of the panel.

The new panel makes it possible to produce a panel covering which makes visible a given amount of irregularity in respect of the size of individual decorative regions, which appear to the user like individual covering elements, for example covering elements of different lengths of a wood floor of natural wood. This is the case although without exception the panels which are laid are of one and the same length.

Laminate panels are known from the state of the art, which are produced in a given length graduation and offered in sets. The production of panels of differing lengths however is extremely cost-intensive. In comparison the proposed panel has the advantage that a joint pattern which is equally varied can be produced with panels which are preferably of the same length and which are inexpensive to produce.

The groove-shaped intermediate joint can be easily milled into the top side of the panel. If the milled surface reaches the core material of the panel, this only involves a narrow strip at which the core material is exposed. That has not been found to give rise to any problems even in relation to core material of wood materials such as medium-density fibreboard (MDF) or high-density fibreboard (HDF).

The impression that a panel covering is genuine can be enhanced by the decorative top side having obtuse edges at many of its edge portions. The obtuse edges also produce a natural impression of the panel covering even at the actual joints between the panels.

Preferably the imitation intermediate joint is of the same free cross-section as that free space which occurs when connecting two panels, by virtue of their mutually adjoining obtuse edges. In a finished panel covering, that provides a highly varied overall image which has a genuine effect, wherein a genuine connecting joint between panels and an imitation intermediate joint on the top side cannot be readily distinguished.

In accordance with an advantageous development it is provided that a coating is provided on the walls of the groove of the imitation intermediate joint. This involves particularly high quality for the panel, in which additional protection is provided for the milled surfaces of the intermediate joint. The coating serves to counteract fibre detachment from the groove walls and the ingress of moisture. The coating can be provided for example in the form of a film, in the form of melamine resin or in the form of lacquering and so forth.

It is also desirable if a coating is provided on the obtuse edges at the edge portions of the top side of the panel in order here also to reduce fibre detachment at the groove walls and possible ingress of moisture.

In order to provide a given controlled variation in the image pattern of a panel covering, it is provided that the decorative regions of the top side of a panel are of different sizes.

A preferred embodiment of a panel is of an elongate and quadrangular configuration.

Desirably the intermediate joint is arranged transversely with respect to the longitudinal axis of the panel. As a result a long panel appears as though it involves a plurality of individual covering elements. The production of an intermediate joint which is arranged transversely with respect to the longitudinal axis of the panel is particularly simple. In order to arouse the impression of a random mingling of different covering elements, the top side of the panel is subdivided by the intermediate joint into rectangular decorative regions of differing lengths.

In accordance with a further alternative it is provided that at least two imitation intermediate joints are arranged in the top side of the panel in different directions. It is possible in that way to provide not only decorative regions which are disposed in succession with each other but in addition decorative regions which are disposed in mutually juxtaposed relationship. A panel can for example have a plurality of mutually juxtaposed rows which are separated by lengthwise intermediate joints, wherein the individual rows have decorative regions which are arranged in succession with each other and which are separated by transversely arranged intermediate joints.

Preferably one of the decorative regions of the top side of the panel has a wood motif, whereby a panel covering which has a proportion of wood or a panel covering which is completely of wood appears natural.

The natural appearance can be enhanced by the wood motifs of mutually adjoining decorative regions at least partially representing a woodgrain pattern which forms a transition from a decorative region, as grown, into the next decorative region. Such an image in terms of the woodgrain patterning is known for example in the case of parquet coverings of natural wood and is desired in that respect. The mutually adjoining parquet elements are naturally grown pieces of wood which are cut out of a trunk. At many intermediate joints however there are woodgrain patterns which do not match each other because they are not cut out of the same piece of wood as grown. The proposed panel is therefore suitable for the production of a panel covering which for example provides a remarkably convincing imitation of the optical impression of a parquet floor. In that respect the wood motif can be a graphically reproduced motif or for example can also comprise natural wood which is provided in the form of a veneer layer.

It will be appreciated that it is also possible for the wood motifs of mutually adjoining decorative regions to at least partially represent woodgrain patterns which are independent of each other.

In that case, in the industrial production of panels of that kind, it is necessary that the intermediate joint, for example if it is milled, can be positioned exactly at the location at which the decorative regions adjoin each other. Accordingly the graphically imaged joint predetermines a milling position. A displacement between the milled groove and a graphic intermediate joint results in production reject. That problem does not occur in the case of decorative regions with a woodgraining pattern which forms a matching transition from one decorative region into the next one. That is because there is no graphically imaged joint which predetermines a precise position for the intermediate joint to be milled. The groove can be milled at any location. There is no fear of production rejects.

Consequently, there are then provided positioning means for a milling tool, which possibly permit an exact milling position to be achieved.

Preferably the panel is in the form of a laminate panel, wherein the decorative top side has at least one graphic representation. Particularly in the case of laminate panels the proposed solution has a positive effect. Known laminate panels hitherto always involved a lack of impression of genuineness because intermediate joints which are only graphically represented and/or are indicated by a thin embossing layer do not afford a satisfactory impression of being genuine. Laminate panels with a surface which has a very natural and genuine effect are already known. In that case for example the graphic representation of wood is provided with an exactly appropriate surface embossing, thereby giving what wood looks like and also what a wood surface feels like. Intermediate joints can now form such a good imitation of a genuine joint between covering elements, that it is not readily possible to establish whether what is involved is an individual covering element or an imitation intermediate joint in the top side of a panel. It will be appreciated that it is possible to provide an intermediate joint irrespective of whether the surface has embossing.

Furthermore the panel can be improved by the provision of fixing edges, wherein at least two mutually opposite fixing edges have locking profiles which act in positively locking relationship.

The invention is illustrated by say of example in a drawing and described in detail with reference to the individual Figures in which:

FIG. 1 shows a panel with two decorative regions and an intermediate joint, and

FIG. 2 shows a panel with two decorative regions, an intermediate joint and chamfered obtuse edges at the edge portions of a decorative top side of the panel.

Looking at FIG. 1, this shows a panel 1 of a multi-layer structure. The panel 1 has a decorative top side 2 and a core material 3. In the present case the decorative top side 2 represents a wood motif. The wood motif is a graphic reproduction of wood. The graphic representation is provided with a transparent coating having a surface structure in the manner of a woodgrain patterning, which matches the graphic representation.

It will be appreciated that, in an alternative configuration, the coating of the top side 2 may also be provided with a surface structure for example in the manner of a woodgrain patterning, wherein that surface structure does not involve any conformity with the graphic representation. A further alternative dispenses with a surface structure in the manner of a woodgrain effect and instead is smooth or is provided with a matt nature.

The decorative top side 2 is provided with an intermediate joint 4. The intermediate joint 4 is of a V-shaped cross-section. In order to produce the intermediate joint 4, a V-shaped groove is milled into the decorative top side 2. The multi-layer decorative top side 2 is severed by the milled groove. The groove extends into the core material 3 of the panel 1. The intermediate joint 4 subdivides the decorative top side 2 into decorative regions 2 a and 2 b. The illustrated woodgrain patterning of the wood motif forms a matching transition from a decorative region 2 a into the other decorative region 2 b, in other words: the woodgrain lines of the woodgrain pattern at the intermediate joint 4 are thus disposed in exactly opposite relationship as if the two decorative regions 2 a and 2 b were wood that had been grown.

In the simplest case the surfaces 4 a and 4 b of the intermediate joint 4 have a milled surface. In the case of a panel 1 of higher quality the milled surface of the intermediate joint 4 is provided with a coating.

The milled surfaces 4 a and 4 b are very narrow. In addition they are disposed in a protected condition in a recess. It is therefore possible to dispense with a coating on the surfaces 4 a and 4 b. Even when using the panel 1 for the production of a floor covering, the surfaces 4 a and 4 b are not subjected to a high level of loading by abrasion because they are disposed in a protected condition in a recess. A loading on the intermediate joint 4 by dirt and moisture has proven to be without problem if the milled core material 3 comprises a medium-density fibreboard (MDF) or a high-density fibreboard (HDF). Depending on the respective quality of the MDF or HDF material, moisture can admittedly penetrate into the surface of the intermediate joint 4. The amount of moisture penetrating thereinto however is small and quickly dries out through the free surfaces 4 a and 4 b.

The proposed panel 1 can be particularly inexpensively produced in its simplest configuration, namely without a coating on the intermediate joint 4. It affords the advantage of a covering element which appears very natural, comprising milled wood elements.

As shown in FIG. 1 the edge portions of the top side 2 are provided with a rectangular corner. The narrow, peripherally extending surfaces of the panel 1 are provided with locking profiles 5 which act in positively locking relationship. The locking profiles 5 of mutually oppositely disposed sides of the panel 1 are of a complementary configuration to each other. That guarantees that similar panels 1 fit to each other and can be connected together.

It will be appreciated that, in a simple embodiment, the panel 1 can also be equipped with conventional tongue-and-groove edges.

The panel 1 as shown in FIG. 1 is of an elongate rectangular shape. The intermediate joint 4 is arranged transversely with respect to the longitudinal extent of the panel 1 and divides the top side 2 of the panel 1 into the two decorative regions 2 a and 2 b of differing lengths.

Usually the panels 1 are offered in a set, wherein such a set either comprises panels 1 with an identical intermediate joint 4 or panels 1 with a varying intermediate joint. In that respect the variants differ in respect of the position of the intermediate joint 4 on the top side 2 of the panel 1 and in respect of the number of intermediate joints 4 in the top side 2 of the panel 1. In that way it is possible to produce an assortment of panels comprising decorative regions 2 a and 2 b involving given length graduations.

FIG. 2, for the sake of simplicity, uses the same references for the same features as in the embodiment shown in FIG. 1. FIG. 2 illustrates a development of the panel 1 which differs from the embodiment of FIG. 1 because the edge portions of the decorative top side 2 are of a different configuration. As shown in FIG. 1 the edge portions of the decorative top side 2 have right-angled corners. The right-angled corners are relatively sharp-edged. Instead, in the embodiment of FIG. 2, the edge portions of the top side are provided with blunted edges. The blunted edges are referred to in accordance with the invention as obtuse edges 6. In the present case the obtuse edges 6 have narrow inclined surfaces. An obtuse edge 6 with the configuration of such an inclined surface forms a bevel. Alternatively each obtuse edge 6 can involve a different geometry, such as for example a radius.

When two panels 1 with bevelled obtuse edges 6 are joined together, then the mutually opposite bevels form a V-shaped recess in the surface of a panel covering. Such a composite recess is of the same cross-section as the intermediate joint 4 which is milled in the top side 2 of the panel 1. Because the intermediate joint 4 and the recess of the V-shaped bevels are of the same cross-section, in the assembled condition of a panel covering they cannot be readily distinguished from each other.

As shown in FIG. 2 the bevels 7 a and 7 b at the long sides of the panel 1 are of a different nature from the bevels 8 a and 8 b at the short sides of the panel 1. The illustrated bevel 8 a at the short side of the panel 1 is provided with a milled surface which does not have any coating at all. The bevels 7 a and 7 b at the long side of the panel 1 in contrast are enclosed with a decorative layer. The term enclosure denotes a one-piece coating of the top side 2 and the bevels 7 a and 7 b. In that case, a decorative layer of the top side 2 of the panel 1 is bent over, in other words, forms an enclosure. The decorative layer is in one piece and extends from one bevel 7 a at a longitudinal side over the entire top side of the panel 1 to the oppositely disposed bevel 7 b at the other longitudinal side. During manufacture the operation of fitting the decorative layer and enclosing it around the bevels 7 a and 7 b at the longitudinal sides of the panel 1 are effected in steps. Firstly the decorative layer of the top side is applied and then in a subsequent layer it is bent over at the edges, whereby the bevels 7 a and 7 b are enclosed.

The bevels 8 a and 8 b at the short sides of the panel 1 are advantageously milled in a later production step. Likewise the intermediate joint 4 is milled in the top side 2 after the decorative layer has been fitted. It can be seen at the bevel 7 a at the longitudinal side, which is shown in FIG. 2, that a woodgrain line 9 of the wood motif goes from the bevel 7 a into the top side 2 of the panel 1. That is possible because the decorative layer is a bendable material.

In regard to the number and the arrangement of the intermediate joint 4, the same applies in regard to the embodiment of FIG. 2, as with the embodiment shown in FIG. 1.

In a particularly high-quality configuration both the intermediate joint 4 and also the bevels 8 a and 8 b at the short sides of the panel can be provided with a coating. The coating can either be a decorative layer which for example has a wood motif or it can be a coating of lacquer or the like which is applied in fluid form.

LIST OF REFERENCES

-   1 panel -   2 decorative top side -   2 a decorative region -   2 b decorative region -   3 core material -   4 intermediate joint -   4 a surface -   4 b surface -   5 locking profile -   6 obtuse edge -   7 a bevel -   7 b bevel -   8 a bevel -   8 b bevel -   9 woodgrain line 

1-15. (canceled)
 16. A panel of laminate structure, wherein there is provided a decorative top side that has at least one imitation intermediate joint by which the top side is subdivided into decorative regions and wherein each decorative region has the appearance of an individual covering element, characterized in that the imitation intermediate joint is in the form of a groove in the decorative top side.
 17. The panel according to claim 16 characterized in that the decorative top side has obtuse edges at least at some of its edges.
 18. The panel according to claim 17 characterized in that the imitation intermediate joint is of the same free cross-section as the free space which is afforded when connecting two panels by virtue of the mutually adjoining obtuse edges thereof.
 19. The panel according to claim 16 characterized in that a coating is provided on the groove walls of the imitation intermediate groove.
 20. The panel according to claim 17 characterized in that a coating is provided on the obtuse edges at the edge portions of the top side of the panel.
 21. The panel according to claim 16 characterized in that the decorative regions of the top side of the panel are of different sizes.
 22. The panel according to claim 16 characterized in that said panel is of an elongate and quadrangular configuration.
 23. The panel according to claim 22 characterized in that the intermediate joint is arranged transversely with respect to the longitudinal axis of the panel.
 24. The panel according to claim 16 characterized in that the top side of the panel is subdivided by the intermediate joint into rectangular decorative regions of differing lengths.
 25. The panel according to claim 16 characterized in that at least two imitation intermediate joints are arranged in the top side of the panel in different directions.
 26. The panel according to claim 16 characterized in that at least one of the decorative regions of the top side of the panel has a wood motif.
 27. The panel according to claim 26 characterized in that the wood motifs of mutually adjoining decorative regions at least partially represent a woodgrain pattern which forms a transition from one decorative region as grown into the next decorative region.
 28. The panel according to claim 26 characterized in that the wood motifs of mutually adjoining decorative regions at least partially represent woodgrain patterns which are independent of each other.
 29. The panel according to claim 16 characterized in that said panel is in the form of a laminate panel and the decorative top side has at least one graphic representation.
 30. The panel according to claim 16 characterized in that there are provided fixing edges, wherein at least two mutually opposite fixing edges have locking profiles which act in positively locking relationship. 